1980 Yamaha XJ 650

LCT Engines Service Manual

PGH45163

10/14/13 rev D

ENGINEERING A NEW GENERATION OF POWER

Table of Contents

Engine Model Number & Serial Numbering System

2-3

General Specifications

4-5

General Troubleshooting

6-7

Advanced Troubleshooting (for authorized LCT technicians)

8-10

Spark Plug Service

10

Engine Oil Level Check

11

Engine Oil Change

11

Engine Oil Recommendations

11

Maintenance Schedule

12

Torque Specifications

13-14

Summer Engine Dimensions 79 136 179 208 291 414

15-20 15 16 17 18 19 20

Winter Engine Dimensions 136 208 (Gen I) 208 (Gen II) 254 291 306 369 414 420

21-29 21 22 23 24 25 26 27 28 29

Engine Model Number & Serial Numbering System The first two lines of an engine’s number is the model number. It is alphanumeric and engraved on the side of the block to the right of the recoil. The third line is alphanumeric and is also the serial number.

Engine Serial Number Sequence

XX XXX XX XXXXX X: Assembly Line Designation (A, B, C, D) Sequential Engine Number Produced Month Engine Series Designation (80V, 40H, 65H, 90H, 12H) Produced Year Example: Engine Serial Number 0965H1200001A represents: “09” is 2009 “65H” is for 208cc Horizontal Engine Series (Refer to Engine Model Number System) “12” is December “00001” is the 1st Engine Produced During Month of December “A” is the Horizontal Assembly Line

LCT Engine Model Numbering System Definition (see chart on page 3): 1. Preproduction - This column is coded and reserved for prototype engines only. 2. Plant - This column is coded and used for LCT internal use only. 3. Design Family - This column is used for emissions regulations and coded for LCT internal use only. 4. Crankshaft - This column indicated whether the PTO shaft (crankshaft) is configured in the engine horizontally or vertically. 5. Shaft - This column is used for the description of the PTO shaft. This will aid in determining what will be the engine’s primary use. 6. Shaft Detail - This column references a chart that designates which LCT engineering drawing corresponds to the PTO shaft.

This is for LCT internal use only.

7. Horsepower - This column is coded to designate the engine’s power output (horsepower) with its corresponding size

(cubic centimeters).

8. Paint Code - This column is coded to which color scheme the engine is equipped with. 9. Starter Type - This column is coded to which type of starting system the engine is equipped with. 10. Options - This column is coded to designate which equipment options the engine is equipped with. 11. Emissions Label - This column is coded for the emissions standards the engine meets. 12. Pack Code - This column is reserved for LCT Packaging Department only. NOTE: The LCT Engine Model and Serial Number Systems is subject to be changed or edited at any time.

Copyright © 2013 Liquid Combustion Technology, LLC

LCT Engine Service Manual: 79, 136, 179, 208, 254, 291, 306, 369, 414 & 420cc 2

Engine Model Number & Serial Numbering System Plant

Design Family

Crankshaft

Shaft

HP

Paint Code

Starter Type

Options

Emissions Label

Pack Code

P

LM Moderate

H Horizontal

T Threaded

150 [1.5hp (63cc)]

1 - JPC Black Recoil (Standard JPC Black)

E - 12VDC/ 120VAC Electric

A - Fixed Speed

E1 - 50 State

S - Single Pack

S

LO ***Hybrid

V Vertical

K Straight-Keyed

175 [ 1.75hp (79cc) ]

2 - Black Tank (Pantone Black G (Glossy))

P- Recoil

B - Manual Choke

E2 - 49 State

M - Multi-Pack

D

LX Extended

P Tapered

200 [ 2.0hp (87cc) ]

3 - Titan Yellow Blower Housing

Z - Recoil/ Electric Provision

C - Catalytic Muffler

E4 - California Preempt

LD Diesel

S Splined (No Attach.)

250 [ 2.5hp (98cc) ]

4 - Black Blower Housing (Pantone Black G (Glossy))

Y - 220VAC Electric

D - Generator Air Filter

E5 - California Exh Only

W1 GEN I Snow

G1 2:1 Reduction (GEAR)

350 [ 3.5hp (106cc) ]

5 - Yellow Recoil (Pantone 1235C)

X - 12V DC with Starter Box

E - Generator Muffler

E7 - European Compliant

W2 GEN II Snow

G2 6:1 Reduction (GEAR)

400 [ 4.0hp (136cc) ]

6 - Yellow Tank (Pantone 1235C)

V - [TBD]

F - No Tank